INSTALLATION, COMMISSIONING &

MAINTENANCE INSTRUCTIONS FOR

TRANSFORMERS
 TABLE OF CONTENTS
SECTION 1: INSTALLATION
1.1 General
1.2 Transport
1.3 Handling & Lifting.
1.4 Receiving the transformer on site.
1.5 Storage prior to energizing.
1.6 Erection on site.
1.7 Connection of transformer terminals.
1.8 Earthing.
1.9 Protective Equipment.
1.10 Insulation resistance.
1.11 Off circuit Tap Changer.

SECTION 2: COMMISSIONING
2.1 Energizing.

SECTION 3: OPERATION
3.1 General precautions.
3.2 Transformer life.
3.3 Parallel operation.
3.4 Frequency.

SECTION 4: MONITORING
4.1 General requirements

SECTION 5: MAINTENANCE
5.1 General.
TABLE OF CONTENTS

5.2 Maintenance in energized condition.

5.3 Maintenance in de-energized condition.
 SECTION 1: INSTALLATION
1.1 General.
This section describes ACEM general experience/recommendations and minimum requirements;
however, it may be overruled or supplemented by local regulations and specific instructions.

1.2 Transport.
The transformer is supplied filled with oil and normally all accessories fitted, except for the larger
units where the radiators and expansion vessels (Conservators) may be dismantled during transport.
When transporting the following should be considered:
- Larger transformers should preferably be positioned with the longitudinal axis in the
direction of movement.
- Vehicle capacity must be adequate for the transport weight of the transformer.
- The transformer must be secured against movement by means of e.g. wooden blocks and
lashes.
- Ensure prevention of damage to bushings, corrugated panels or radiators and accessories.
- Adapt vehicle speed to the road conditions.

1.3 Handling & Lifting.

Only approved and suitable lifting equipment shall be used. Use a forklift only on transport pallets or
transformer bottom. Do not apply any load to corrugated fins or radiators and their supports. Use
the provided lifting lugs only. When lifting a transformer with cable boxes on the cover, special care
must be taken. When hydraulic jacks are used, only provided jacking points shall be used, and in
such a way that twisting forces on the transformer tank are avoided.

1.4 Receiving the transformer on site.

Transformers manufactured by ACEM are thoroughly tested and inspected prior to shipping, but
once arrived on site the following should be checked.

SECTION 1: INSTALLATION
- Delivery note against goods received, details of transformers can be seen on the rating and
diagram plate.
- If there are any visual oil leaks.
- Any external damage.

In case damage is detected during the inspection, do any of the following:

- Take required action to avoid further damage.
- Contact ACEM Transformers.
- Record details of the damage

Note!
No repairs should be started until responsibilities are clarified and actions are agreed upon all
involved parties
1.5 Storage prior to energizing
When storage of the transformer is required, the following should be adhered to:
- Store in dry and clean area with a solid foundation to prevent any possibilities of mechanical
damage.
- The transformer should be placed on supports to allow for ventilation under the bottom of
the base.
- The oil conservator and dehydrating breather must be checked to ensure that dry air is
breathed. (Conservator and free breathing types only).
- Avoid condensation in auxiliary terminal and cable boxes.
- Although all gasket joints are torqued in the factory it is very important that all nuts be
checked on site. Torque bolts to the settings listed in the table under 1.7 below.

1.6 Erection on site

When installing a transformer, give careful consideration to accessibility, safety, ventilation and ease
for inspection. Make sure the foundation for mounting the transformer is entirely adequate with
regards to its mass.

1.7 Connection of electrical terminals

- Adhere to local authority’s safety- and regulations for electrical installations.
- Conductors, bus bars and cables shall be installed such that minimal mechanical stress is
transferred to the bushings.
- Nuts should be adequately locked.
- Flexible connectors shall be used where relevant
- High voltage connection is normally performed by copper cables and copper cable lugs. In
some cases, heat shrinkable connectors or elbow connectors are used.
- For aluminum-copper joints the copper is coated with tin, or bi-metal sheets (one side of
copper and the other of aluminum) can be used between the joints.
- The aluminum surface must be larger than the copper surface.
- Aluminum parts shall always be placed above copper parts so that water cannot drain from
the copper parts onto the aluminum due to corrosion possibilities.
- It must be remembered that good contact between joined aluminum surfaces can be
achieved only if the “none conducting” oxide film is removed with a wire brush, file or
similar tool immediately before joining. Apply a thin protective film of grease (neutral
Vaseline) as this will prevent renewed oxidation.
- Jointing compound, which prevents the access of air and humidity into joints, must be used
in the joint. The zinc crystals of the compound break down the layer of oxide on the
aluminum.
- Minimum electrical clearances shall be adhered to (Refer to SANS 780 or IEC60076).
- Suitably strong steel bolts and nuts have to be used for tightening connection joints. The
tightening torque’s given below are recommended to be used in external transformer joints.
- Tightening torques for the MV & LV transformer bushings will be itemized on the relevant
drawings which will form part of the data pack.

Thread size Grade 8.8 not plated in Nm Grade 8.8 plated in Nm. e.g.,
hot
dipped galvanized, zinc etc.
M6 12 8
M8 28 20
M10 56 40
M12 98 70
M16 244 174
 1.8 Earthing
Earth the transformer at the earthing terminals provided. Earthing resistance must be in
accordance with electricity utilities or national standards.

1.9 Protective Equipment

- When equipment below is provided check settings and functions:
- Thermometer with contacts for alarm and trip signals.
- Oil level indicator with contacts for alarm signals.
- Gas relay with contacts for alarm and trip signals.
- Pressure relief device with contacts for trip signal.
- Winding thermometer settings.
Based on a 40˚ Celsius ambient temperature the following settings can be used.
Recommended settings for ONAN transformers Alarm Tripping
Oil thermometer setting 95˚C 105˚C
Oil thermometer setting, when combined with a 80˚C 105˚C
winding temperature indicator
Winding temperature indicator setting 100˚C 110˚C

1.10 Insulation Resistance. (Megger Test)

If possible, check the insulation resistance between HV and LV as well as windings to earth.
Minimum value @ 2.5kV is 1000 MΩ up to 33kV rated voltage.

1.11 Off Circuit Tap Changer

Compare the voltage ratio of the transformer and the network voltages and select the suitable tap
position. Note that the Tap-changer is to be used for primary voltage variation only. Boosting of
secondary voltage with Tap-changer is only allowed when specifically designed for.
SECTION 2: COMMISSIONING
SECTION 2: COMMISSIONING
Prior to energizing, the transformer has to be checked. When applicable the following items should
be checked:

Earthing of: Transformer tank, current transformers, surge arresters etc.

- Current transformers: Check polarity, and that all secondary CT circuits are short circuited
before energizing the transformer. If a current transformer is not in use it must be short
circuited and earthed. An open circuited current transformer gives hazardous voltages and is
dangerous to personnel and equipment.
- Protective equipment: Check that all alarm and trip signals from protective equipment are
functioning, such as thermometers, oil level indicators, Buchholz relays, pressure relieve
valves etc.
- An oil sample should be taken and analyzed to check that the oil dielectric withstand voltage
fulfils the requirements in IEC60076 or SANS780, normally > 50kV for systems up to 33kV.
Notes!
When connecting distribution transformers to the network, fuses may blow immediately due to high
inrush current. This does not necessarily mean that there is a fault in the transformer. Replace blown
fuses and try energizing again as the magnitude of the inrush current is a statistical variable with
large spread.

After the transformer has been energized, air may cause a gas relay alarm. It could be a false alarm
caused by an air bubble, which has been trapped inside the core and winding or under the cover. If
the air is not odorless an oil / gas sample should be taken for analysis
 SECTION 3: OPERATION
3.1 General precautions.
- Do not energize or perform maintenance on the transformer without proper earth
connection.
- Never work on transformers or any installed electrical equipment alone.
- Do not change the position of the off-circuit tap-changer while the transformer is energized.

3.2 Transformer life expectancy.

Typical lifetime of a distribution transformer under normal conditions is approximately 25 to 30
years. Solid insulation materials consist mainly of organic materials. These materials change over
time and are affected by temperature, humidity and oxygen. Ageing consists of several oxidation
processes where the chemical reaction rate increases strongly with temperature therefore the life
expectancy of a transformer depends mainly on its accumulated load cycle, ambient temperature,
moisture and oxygen in the oil. This varies with transformer loading and frequency of maintenance.
The IEC 60354 specification provides guidelines on loading of oil - immersed transformers.

3.3 Parallel operation.

When two or more transformers are connected in parallel the following is required:
- Only transformers having the same secondary voltage can operate in parallel.
- Transformers must have the same voltage ratio.
- The short-circuit impedance of the paralleled transformers must be the within +-10% of each
other.
- The power rating of the transformers should not deviate more than 30%.

3.4 Frequency.
Transformers are designed for 50 Hz operation unless otherwise requested at tender stage.

SECTION 3: OPERATION
 SECTION 4: MONITORING
4.1 General requirements.
Requirements are,
- Periodical recording of protection indicators and visual inspection.
- Oil condition monitoring

Periodically recording is normally done when the transformer is energized. The indicators recorded
are, oil level, top oil temperature, winding temperature and load current. The equipment to be
monitored will depend on the type of transformer and the protection equipment fitted. Depending
on the importance of the transformer the recording of these indicators could be done weekly or
monthly. A visual inspection for oil leaks and breather silica gel can be performed at the same time.

Periodical analysis and conditioning of the oil in a transformer is by far the most widely used method
for monitoring the general condition of a transformer. The condition of the oil and, of the
transformers insulation system, can be determined by taking oil samples from the transformer for
dissolved gas analysis (DGA) and other tests. The tests are comprehensively described for example,
in the IEC Standard 60296 and the Guides 60422 and 60567. The presence of an incipient fault in a
transformer will normally be detected by monitoring trends and total gas counts.

Normally oil samples are taken when the transformer is energised please ensure that necessary
safety precautions are taken. The most common frequency for oil condition monitoring is annually,
however when there is suspicion of an incipient fault in progress, the oil samples should be taken
more frequently, e.g. every three months.
SECTION 4: MONITORING
 SECTION 5: MAINTENANCE
5.1 General requirements.
The primary purpose of transformer maintenance is to ensure the internal and external parts of the
transformer and accessories are kept in good condition.
Transformer maintenance can be done periodically or as condition-based maintenance. The latter is
usually the most economical way of doing maintenance. Recommended maintenance are then done
based on one or more of the following; inspections, analysis of oil samples, electrical measurements,
test of equipment, measurement of temperatures by using a heat sensitive camera, monitoring (off-
line and/or on-line).

5.2 Maintenance in the energized condition.

For personal safety reasons, only a limited amount of maintenance activities should be performed
on the transformer when it is in operation. When necessary safety precautions have been taken the
following maintenance can be done in energized condition:
- Inspection for oil leaks, cracks in porcelain bushings, checks of auxiliary equipment etc.
- Check drying material in the dehydrating breather. (Free breathing units)
- Measurement of temperatures of connections, bushings etc. by using a heat sensitive
camera

5.3 Maintenance in the de-energized condition.

Before starting maintenance work, the transformer must be disconnected from the network and
earthed. When the circuit breaker and the isolator have been opened, they shall be locked in open
position to prevent inadvertently closing during maintenance work.

5.3 Maintenance in the de-energized condition.

Before starting maintenance work, the transformer must be disconnected from the network and
earthed. When the circuit breaker and the isolator have been opened, they shall be locked in open
position to prevent inadvertently closing during maintenance work.

SECTION 5: MAINTENANCE
Items to be considered are:
- Bushing gaskets; if leaks occur, tightening usually will help, if the gasket has lost its elasticity,
it must be replaced. The reason for loss of elasticity could be excessive heating or over
tightening.
- Welded joints. Leaking joints can be repaired only by welding. A skilled welder and a welding
instruction are required. Contact ACEM for further instructions.
- Cleaning contaminated bushings (cleaning agent e.g. methylated spirits, do not use
thinners).
- Cleaning glasses on gas relay, thermometer and liquid level indicator.
- Functional inspection and testing of applicable accessories.
- Move Tap-changer through all positions a few times.
- Oil sampling from bottom drain valve when required.
- Check drying material in the dehydrating breather.
- - Clean and touch-up paint work.
 ARMCOIL AFRIKA (PTY) LTD

127 Albertina Sisulu Road, Technikon, Roodepoort

+27 11 763 2351
[email protected]
www.armcoil.co.za